weber 4000 User Manual
Serial Number
Please use this number in registering your warranty
and any correspondence with the factory.
GENESIS®4000 Series
Natural Gas Barbecue
Owner’s Manual
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
NOTICE TO INSTALLER: These
instructions must be left with the owner
and the owner should keep them for
future use.
WARNING: Follow all leak check
procedures carefully in this manual prior
to barbecue operation. Do this even if
barbecue was dealer assembled.
WARNING: Do not try to light this
appliance without reading "Lighting"
instructions section of this manual.
THIS GAS APPLIANCE IS DESIGNED FOR
OUTDOOR USE ONLY.
FOR YOUR SAFETY
If you smell gas:
1. Shut off gas to the appliance.
2. Extinguish any open flame.
3. Open lid.
4. If odor continues, immediately call
your gas supplier or your fire
department.
86016 6/96
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DANGER
Failure to follow the Dangers, Warnings and Cautions contained in this Owner’s
Manual may result in serious bodily injury or death, or in a fire or an explosion causing
damage to property.
WARNINGS
■ Do not store a spare or disconnected LP tank under or near this barbecue.
■ Improper assembly may be dangerous. Please carefully follow the assembly instructions in this manual.
■ After a period of storage, and/or nonuse, the Weber Gas Barbecue should be checked for
gas leaks and burner obstructions before using. See instructions in this manual for correct
procedures.
■ Do not operate the Weber Gas Barbecue if there is a gas leak present.
■ Do not use a flame to check for gas leaks.
■ Combustible materials should never be within 24 inches of the top, bottom, back or sides of your
Weber Gas Barbecue.
■ Do not put a barbecue cover or anything flammable on or in the storage area under the barbecue.
■ Your Weber Gas Barbecue should never be used by children.
■ You should exercise reasonable care when operating your Weber Gas Barbecue. It will be hot during
cooking or cleaning, and should never be left unattended.
■ Should the burners go out during operation, turn all gas valves off. Open the lid and wait five minutes
before attempting to relight, using the lighting instructions.
■ Do not use charcoal or lava rock in your Weber Gas Barbecue.
■ Never lean over open grill or place hands or fingers on the front edge of the cooking box.
■ Should a grease fire occur, turn off all burners and leave lid closed until fire is out.
■ Do not enlarge valve orifices or burner ports when cleaning the valves or burners.
■ The Weber Gas Barbecue should be thoroughly cleaned on a regular basis.
■ LP gas is not natural gas. The conversion or attempted use of natural gas in an LP unit or LP gas in a
natural gas unit is dangerous and will void your warranty.
■ Do not attempt to disconnect any gas fitting while your barbecue is in operation.
■ Use heat-resistant barbecue mitts or gloves when operating barbecue.
LP GAS UNITS ONLY:
■ Use the regulator that is supplied with your Weber Gas Barbecue.
■ Do not attempt to disconnect the gas regulator or any gas fitting while your barbecue is in operation.
■ A dented or rusty LP tank may be hazardous and should be checked by your liquid propane supplier.
Do not use an LP tank with a damaged valve.
■ Although your LP tank may appear to be empty, gas may still be present, and the tank should be
transported and stored accordingly.
■ If you see, smell or hear the hiss of escaping gas from the LP tank:
1. Get away from LP tank.
2. Do not attempt to correct the problem yourself.
3. Call your fire department.
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WARRANTYWARRANTY
Weber-Stephen Products Co. (Weber) hereby
warrants to the ORIGINAL PURCHASER of
this Weber Gas Barbecue that it will be free of
defects in material and workmanship from the
date of purchase as follows:
Aluminum Castings, 10 years,
Cooking Grates, 3 years,
Stainless Steel Flavorizer Bars, 5 years,
All Remaining Parts, 5 years,
when assembled and operated in accordance
with the printed instructions accompanying it.
Weber may require reasonable proof of your
date of purchase. THEREFORE, YOU
SHOULD RETAIN YOUR SALES SLIP OR
INVOICE.
This Limited Warranty shall be limited to the
repair or replacement of parts which prove
defective under normal use and service and
which on examination shall indicate, to
Weber's satisfaction, they are defective. Before
returning any parts, contact Weber-Stephen
Products Co. Customer Service Center. If
Weber confirms the defect and approves the
claim, Weber will elect to replace such parts
without charge. If you are required to return
defective parts, transportation charges must be
prepaid. Weber will return parts to the
purchaser, freight or postage prepaid.
This Limited Warranty does not cover any
failures or operating difficulties due to accident,
abuse, misuse, alteration, misapplication,
vandalism, improper installation or improper
maintenance or service, or failure to perform
normal and routine maintenance, including but
not limited to damage caused by insects within
the burner tubes, as set out in this owner's
manual.
Deterioration or damage due to severe
weather conditions such as hail, hurricanes,
earthquakes or tornadoes, discoloration due to
exposure to chemicals either directly or in the
atmosphere, is not covered by this Limited
Warranty.
There are no other express warrants except as
set forth herein and any applicable implied
warranties of merchantability and fitness are
limited in duration to the period of coverage of
this express written Limited Warranty. Some
states do not allow limitation on how long an
implied warranty lasts, so this limitation may
not apply to you.
Weber is not liable for any special, indirect or
consequential damages. Some states do not
allow the exclusion or limitation of incidental or
consequential damages, so this limitation or
exclusion may not apply to you.
Weber does not authorize any person or
company to assume for it any other obligation
or liability in connection with the sale,
installation, use, removal, return, or
replacement of its equipment; and no such
representations are binding on Weber.
This Warranty applies only to products sold at
retail.
WEBER-STEPHEN PRODUCTS CO.
Customer Service Center
250 South Hicks Road
Palatine, IL 60067-6241
(800) 446-1071
© 1996 Weber. Weber, , Genesis, Flavorizer and Crossover are
registered U.S. trademarks; Perma-Mount, Gas Catcher,
FlameCheck, Steam-N-Chips, Spider Stopper, and Warm-Up are
U.S. trademarks of Weber-Stephen Products Co., 200 East Daniels
Road, Palatine, IL 60067-6266. U.S.A. Genesis Gas Barbecues are
covered under the following patent nos.: U.S.A. #4,677,964;
4,727,853; #4,777,927; #4,829,978; #4,860,724; #4,941,817;
#4,966,125; #5,070,776; #D293,067; #D316,355; Canada: Rd
1987 Reg. #58,034; #1,279,540; #1,283,586; #1,300,994;
#1,300,995. Printed in the U.S.A.
4
PATENTS AND TRADEMARKS
5
Contents
WARNINGS................................................................ 2
Warranty & Patents.................................................. 3-4
General Instructions.................................................... 6
Assembly ............................................................... 7-24
Operating Instructions
Lighting ....................................................... 25-27
Cooking ............................................................ 28
Storage and/or Nonuse .................................... 28
Cleaning ........................................................... 28
Steam-N-Chips Smoker ................................... 29
Troubleshooting & Maintenance
Annual Maintenance ........................................ 30
General Maintenance.................................. 31-34
Troubleshooting .......................................... 35-36
Parts Listing .............................................................. 39
FEATURES:
a) Convenient tables and racks.
b) Heavy gauge porcelain-on-steel lid seals in heat.
c) Rapid read thermometer for precision cooking.
d) Stainless Steel Flavorizer Bars vaporize just the
right amount of drippings for flavoring.
e) Separate burners for temperature control.
f) Crossover Ignition System with Gas Catcher Ignition
Chamber.
g) Weber Warm-Up Basket for additional cooking or
warming space.
h) Locking casters for additional portability.
i) FlameCheck Safety System automatically shuts off
gas to the burners if the flame goes out.
j) Steam-N-Chips Smoker lets you add genuine smoke
flavor to any food prepared on this grill.
k) Side burner for making sauces, gravies, etc.,while
main grill is in use.
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General Instructions
Your Weber Gas Barbecue is a portable outdoor
cooking appliance. With the Weber Gas Barbecue you
can grill, barbecue, roast and bake with results that are
difficult to duplicate with indoor kitchen appliances. The
closed lid and Flavorizer Bars produce that "outdoor"
flavor in the food.
The Weber Gas Barbecue is portable so you can easily
change its location in your yard or on your patio.
Portability means you can take your Weber Gas
Barbecue with you if you move.
The natural gas supply is easy to use and gives you
more cooking control than charcoal fuel.
■ These instructions will give you the minimum
requirements for assembling your Weber Gas
Barbecue. Please read the instructions carefully
before using your Weber Gas Barbecue. Improper
assembly can be dangerous.
■ Not for use by children.
■ If there are local codes that apply to portable gas
grills, you will have to conform to them. If there are
no local codes, you must conform to the latest
edition of the National Fuel Gas Code: ANSI Z
223.1.
■ This Weber Gas Barbecue is designed for natural
(piped in city) gas only. Do not use Liquid Propane
(LP) bottled gas.The valves, orifices and hose are
for natural gas only.
■ Do not use with charcoal fuel.
■ Check that the area under the control panel and the
bottom tray are free from debris that might obstruct
the flow of combustion or ventilation air.
■ The area around the LP tank must be free and clear
from debris.
For Installation in Canada
These instructions, while generally acceptable, do not
necessarily comply with the Canadian Installation
codes, particularly with piping above and below ground.
In Canada the installation of this appliance must comply
with local codes and/or Standard CAN/CGA-B149.1
(Installation Code for Natural Gas Burning Appliances
and Equipment).
Storage
■ The gas must be turned OFF at the natural gas
supply when the Weber Gas Barbecue is not in use.
■ When the Weber Gas Barbecue is stored
indoors, the gas supply must be disconnected.
Operating area
WARNING: Only use this barbecue outdoors in a
well ventilated area. Do not use in a garage,
building, breezeway or any other enclosed area.
■ Never use your Weber Gas Barbecue under an
unprotected combustible roof or overhang.
■ Your Weber Gas Barbecue is not intended to be
installed in or on recreational vehicles and/or boats.
■ Do not use combustible materials within 24 inches
of the top, bottom, back or sides of the grill.
■ The entire cooking box gets hot when in use. Do not
leave unattended.
■ Keep any electrical supply cord and the fuel supply
hose away from any heated surface.
■ Keep the cooking area clear of flammable vapors
and liquids, such as gasoline, alcohol, etc., and
combustible materials.
Gas supply testing
■ Disconnect your Weber Gas Barbecue when the
gas supply is being tested at high pressures. This
appliance and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of 1/2 psig (3.5 kPa).
■ Turn off your Weber Gas Barbecue when the gas
supply is being tested at low pressures. This
appliance must be isolated from the gas supply
piping system by closing its individual manual
shutoff valve during any pressure testing of the gas
supply piping system at the pressure equal to or
less than 1/2 psig (3.5 kPa).
Step 1
Check package contents
Cooking box
(assembly)
Lid
(assembly)
Hose
Bottom tray
Work table
Two accessory trays
Two swing tables
7
Assembly
Tools needed
Screwdrivers, regular
and Phillips
Hammer
7/16, 5/8, 11/16, and 3/4 inch open-end or two
adjustable wrenches
Pliers
Block of wood
Supplies needed
You will need a soap and water solution to check for gas
leaks. (See Step "Check for gas leaks.")
Note - The hardware size of nuts, bolts and screws is
given. For example "1/4-20 x 2 inch bolt" means a bolt
1/4 inch in diameter with 20 threads to the inch, 2 inches
long. On a small screw for example, "6-32 x 1/2 inch
screw" means a number 6 screw, with 32 threads to the
inch, 1/2 inch long.
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While we give much attention to our products,
unfortunately an occasional error may occur.
If a part is missing, do not go back to the store.
Call the Weber Customer Service Center toll free
1-800-446-1071 to receive immediate assistance.
Have your owner’s manual and serial number of the
barbecue available for reference.
Serving tray
Control panel
Front panel
Left frame
Wheel frame
Two frame connectors
Five long Flavorizer Bars
Seven short Flavorizer Bars
Two wheels
Axle
8
Right frame
Caster frame
Cooking grate
Narrow cooking grate
Warming rack
Warm-Up Basket
Thermometer
Two aluminum drip pans
Catch pan
Catch pan holder
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Right hand slide bar assembly
Assembly consists of:
Right hand slide bar
Support
Slide
Left hand slide bar assembly
Assembly consists of:
Left hand slide bar
Support
Slide
Side burner assembly
Burner grate
Side burner knob
Two side burner locks
Steam-N-Chips Smoker body
Steam-N-Chips Smoker flue
Steam-N-Chips Smoker
water pan
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Four 10-24 x 1 3/4 machine screws
(actual size)
Four 10-24 hex nuts
(actual size)
Nineteen 1/4 inch nylon washers
(actual size)
1/4-20 keps nut
Two hair pin cotters
Two swing table end brackets
Two casters
Check contents of hardware packs
Three burner control knobs
FlameCheck button
Three tool holders
Four tubing plugs
(two are spares)
Two wheel hubcaps
(actual size)
Two hinge pins
(hardware size: 1/4 x 1 1/2 inch clevis pin)
(actual size)
Five 1/4-20 x 2 inch bolts
(actual size)
Six 1/4-20 x 1/2 inch bolts
(actual size)
Manifold bracket
11
Step 2
Assemble wheels
You will need: axle, two wheel hubcaps, two wheels,
wheel frame, hammer and a block of wood.
Place one end of the axle on the block of wood (or other
protected surface). Tap on one hubcap.
Put one wheel on the axle, WEBER side toward the
hubcap. Slide the axle through the frame. Add the other
wheel, WEBER side out. Tap on the hubcap. Figure 1.
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Figure 1
Step 3
Assemble frame
You will need: left frame, right frame, two nylon
washers, two 1/4-20 x 1/2 inch bolts and a 7/16 inch
wrench.
Note - Work on carpeted area (on grass, or on one of
the boxes) to protect the finish during frame assembly.
Put the frame pieces so the leg tabs are up. Put the right
frame to your right and left frame to your left. Figure 2.
Slip the two frame halves together with the tabs inside
,
until the tabs of the right frame are inside the left frame
and the holes align. Figure 2 (a).
Slip washers over bolts; insert and tighten bolts. (If you
try to insert a bolt and there are no holes, you have the
left frame turned the wrong way. Turn the left frame
around.) Figure 2 (b).
Left frame
Leg tabs
Frame tabs
Figure 2
(a)
(b)
Right frame
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Step 4
Continue frame assembly
You will need: frame assembly, wheel frame assembly,
front panel, caster frame, four 1/4-20 x 1/2 inch bolts,
four nylon washers and a 7/16 inch wrench.
Place the caster frame onto the tabs of the left frame
with the dimple to the inside. Figure 3. Place the wheel
frame onto the tabs of the right frame with the dimple to
the inside. Figure 3.
The leg tabs must be on the inside of the frames.
Add front panel with the hole down and to your right.
Add the washers to the bolts, insert in the holes as
shown. Only start the bolts at the wheel frame,
figure 3 (a) & (b), and tighten the bolts at the
caster frame.
Dimples to
the inside
Only start
this bolt
Wheel frame
Caster frame
Figure 3
(a)
(b)
Step 5
Complete frame assembly
You will need: partial frame assembly, two frame
connectors, four 1/4-20 x 2 inch bolts, four nylon
washers and a 7/16 inch wrench.
Hold one frame connector between the caster and
wheel frame. Add nylon washers to the bolts. Put the
bolts through the frame and screw into frame connector.
Tighten.
Repeat procedure with the other frame connector.
Figure 4.
Figure 4
Step 6
Insert casters
You will need: frame assembly and two casters.
Push the casters firmly into the inserts in the ends of the
caster legs. Figure 5.
Figure 5
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